Complex layered structure

Abstract

The present invention provides a multilayer structure having a glass layer with a thickness of 10µm to 200µm and a resin layer, wherein a stacked structure of one glass layer and one resin layer is used as a unit stacked structure, and the number of the unit stacked structures in the thickness direction of the multilayer structure is 5 to 20,000.

Description

Multi-layer structure The present invention relates to a multi-layer structure having glass layers and resin layers. A multi-layer structure formed by overlapping multiple layers of glass and resin film is known as a composite material that has both the rigidity of glass and the toughness of resin. This multi-layer structure has the following effect, namely, for high-intensity impact, the external impact is drastically reduced by repeatedly destroying the glass and absorbing the impact of the resin. Due to such characteristics, this multi-layer structure is widely used as bulletproof glass and security glass for defense to prevent cracking and damage due to external impact. Previous technical documents Patent documents Patent Document 1: Japanese Patent Application Laid-Open No. 2003-192402 Problem to be Solved by the Invention: Conventional multi-layer structures use multiple sheets of flat glass several millimeters thick. While the greater the number of layers, the higher the impact resistance, the higher the specific gravity of glass, this poses a weight issue. Curved glass, formed by bending glass to expand its applications, has been used for display cases, architectural components, and other applications from a design perspective. However, applying multi-layer structures to curved glass requires thermally deforming the structure into a curved shape, which is impractical due to thermal decomposition of the resin layer at the glass's softening point of several hundred degrees Celsius. While there are methods that pre-curve the glass and then laminate it with resin, achieving high productivity is difficult. Furthermore, if a cylindrical multi-layer structure could be obtained, it could be used as a high-strength piping material. While it has been possible to provide chemical equipment and the like with transparent, unbreakable, visually recognizable piping with a glass-treated metal surface, stacking glass tubes and resin tubes in multiple layers has been extremely difficult. The present invention has been made in view of the above-mentioned points, and its object is to provide a multi-layer composite structure having a glass layer and a resin layer, and a multi-layer structure that can be formed into any shape. The multi-layer structure comprises a glass layer having a thickness of 10µm to 200µm, and a resin layer, wherein a laminated structure of one glass layer and one resin layer is defined as a unit laminated structure, and the number of such unit laminated structures in the thickness direction of the multi-layer structure is 5 to 20,000 layers. According to the disclosed technology, it is possible to provide a multi-layer composite structure having a glass layer and a resin layer and capable of being formed into any shape. Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In each of the drawings, the same components are denoted by the same reference numerals, and overlapping descriptions may be omitted. [Multi-layer Structure] Fig. 1 is a perspective view illustrating a multi-layer structure according to the present embodiment. As shown in Fig. 1 , a multi-layer structure 10 has a structure in which glass layers 11 and resin layers 12 are alternately arranged in a plurality of layers. More specifically, the multi-layer structure 10 has a structure in which a laminated structure consisting of one glass layer 11 and one resin layer 12 is defined as a unit laminated structure 13. In the thickness direction (the lamination direction) of the multi-layer structure 10, a plurality of unit laminated structures 13 are laminated and fixed so that the glass layers 11 and the resin layers 12 are alternately arranged. It should be noted that the unit laminated structures 13 may also be laminated with adhesive layers or bonding layers interposed therebetween. In the unit laminate structure 13, for example, the glass layer 11 and the resin layer 12 have the same thickness. However, in the unit laminate structure 13, the glass layer 11 and the resin layer 12 may have different thicknesses. Furthermore, a combination of multiple unit laminate structures having different laminate thicknesses may be used, in which the glass layer 11 and the resin layer 12 have arbitrary thicknesses. The number of layers in the unit stacked structure 13 is 5 to 20,000, preferably 10 to 1,000, and more preferably 20 to 100. Within this range, a multi-layer structure 10 that achieves both lightness and impact resistance can be obtained. It should be noted that in the various figures, for ease of illustration, the number of layers in the unit stacked structure 13 may be less than 5. However, in practice, the number of layers in the unit stacked structure 13 is 5 or more and 20,000 or less. FIG2 is a perspective view illustrating a multi-layer structure according to a first variation of this embodiment. The structure of the multi-layer structure can be as shown in FIG1 , where the main surfaces of the glass layer 11 and the resin layer 12 are flat, or as shown in FIG2 , where the main surfaces of the glass layer 11 and the resin layer 12 are curved, as shown in FIG2 , where the main surfaces of the glass layer 11 and the resin layer 12 are curved. Alternatively, the structure of the multi-layer structure of this embodiment can be a combination of a portion where the main surfaces of the glass layer 11 and the resin layer 12 are flat and a portion where the main surfaces are curved. FIG3 is a perspective view illustrating a multi-layer structure according to a second variation of this embodiment. As shown in FIG3 , when unit layer structures 13 are stacked in a roll, a cylindrical shape can typically be formed. In FIG3 , S near the center of multi-layer structure 10B represents a space. As shown in FIG4A , the cross-section of the columnar structure of the multi-layer structure 10B is, for example, a circle. However, the cross-section of the columnar structure of the multi-layer structure 10B is not limited to a circle and may be an ellipse as shown in FIG4B , or a combination of straight lines and curves as shown in FIG4C and FIG4D . The cross-section in FIG4C is a rectangular shape with rounded corners, while the cross-section in FIG4D is a hexagonal shape with rounded corners. [Glass layer] The glass layer 11 is not particularly limited, and appropriate glass can be used depending on the purpose. According to the classification based on the composition, the glass layer 11 can be exemplified by alkali-lime glass, borate glass, aluminosilicate glass, quartz glass, etc. In addition, according to the classification based on the alkali component, alkali-free glass and low-alkali glass can be exemplified. It is preferred that the alkali metal component (e.g., Na 2O, K 2O, Li 2O) is 15 wt% or less, more preferably 10 wt% or less. The thickness t1 of the glass layer 11 is, for example, not less than 10 μm and not more than 200 μm. Here, a glass layer having a thickness of 10 μm to 200 μm means a glass layer having an average thickness of 10 μm to 200 μm. Considering the surface hardness, airtightness, and corrosion resistance of glass, the thickness t1 of the glass layer 11 is preferably 10µm or greater. Furthermore, since it is desirable for the single glass layer 11 to have thin-film-like flexibility while achieving a curved surface structure, the thickness t1 of the glass layer 11 is preferably 200µm or less. A range of 50µm to 100µm is particularly preferred. The light transmittance of the glass layer 11 at a wavelength of 550 nm is preferably 85% or more. The refractive index of the glass layer 11 at a wavelength of 550 nm is preferably 1.4 to 1.65. The density of the glass layer 11 is preferably 2.3 g / cm 3 ~3.0g / cm 3 , more preferably 2.3 g / cm 3 ~2.7g / cm 3 . The method for forming the glass layer 11 is not particularly limited, and an appropriate method can be adopted depending on the intended purpose. Typically, the glass layer 11 can be produced by melting a mixture containing a main raw material such as silicon and / or aluminum oxide, a defoaming agent such as sodium sulfate and / or antimony oxide, and a reducing agent such as carbon at a temperature of approximately 1400°C to 1600°C, forming the mixture into a thin plate, and then cooling the mixture. Examples of methods for forming the glass layer 11 include the slot-draw method, the fusion method, and the float method. The glass layer formed into a plate by these methods can also be chemically polished using a solvent such as hydrofluoric acid to reduce thickness and improve smoothness, as needed. [Resin Layer] As used herein, a resin layer refers to a layer containing a resin component. A resin layer may also include additives such as inorganic particles to form the resin layer. Specifically, a layer consisting solely of an adhesive layer, a bonding layer, or an interlayer film is considered a resin layer. Figure 5A illustrates an example where the resin layer 12 consists solely of an adhesive layer, a bonding layer, or an interlayer film. Furthermore, when a flexible resin film and a glass layer are laminated via an adhesive layer or bonding layer, the layer comprising the resin film and the adhesive layer or bonding layer corresponds to the resin layer. In other words, in a unit laminate structure, the resin layer may be composed of a flexible resin film and an adhesive layer or bonding layer disposed between the glass layer and the resin film. Figure 5B shows an example in which resin layer 12 is composed of a resin film 121 and an adhesive layer 122. Resin layer 12 may also include an adhesive layer in place of adhesive layer 122. The thickness t2 of the resin layer 12 is, for example, 0.1 μm to 2 mm. Here, a resin layer having a thickness of 0.1 μm to 2 mm means a resin layer having an average thickness of 0.1 μm to 2 mm. [Resin Film] Examples of flexible resin substrates include polyether sulfide resins; polycarbonate resins; acrylic resins; polyester resins such as polyethylene terephthalate resins and polyethylene naphthalate resins; polyolefin resins; cycloolefin resins such as norbornene resins; polyimide resins; polyamide resins; polyimide-amide resins; polyarylate resins; polysulfide resins; and polyetherimide resins. Among these, polyethylene terephthalate, polycarbonate, and polyolefin are preferred. The color of the resin substrate is not particularly limited, but opaque resin substrates are not preferred from the perspective of transparency. The thickness of the resin film is preferably approximately 25 µm to 1 mm. A thickness of 50 µm to 500 µm is particularly preferred. [Adhesive, Tackifier, Interlayer Film] Any suitable adhesive or tackifier can be used as the adhesive or tackifier. Specific examples include acrylic adhesives, silicone adhesives, rubber adhesives, UV-curable acrylic adhesives, UV-curable epoxy adhesives, thermosetting epoxy adhesives, thermosetting melamine adhesives, and thermosetting phenol adhesives. Alternatively, the interlayer may be an ethylene-vinyl acetate copolymer (EVA) interlayer, a polyvinyl acetal resin such as polyvinyl butyral (PVB), or a polyvinyl halide resin such as polyvinyl chloride (PVC). The thickness of the adhesive layer, the bonding layer, and the interlayer is not particularly limited as long as it is within the range of the thickness of the resin layer. [Method for Manufacturing a Multi-Layer Structure] (Case in which the Resin Layer 12 Consists Only of an Adhesive Layer, Adhesive Layer, or Intermediate Film) Figure 6 illustrates a method for manufacturing a multi-layer structure in which the resin layer consists only of an adhesive layer. When the resin layer 12 consists only of an adhesive layer, for example, a multi-layer structure 10B can be manufactured using the method shown in Figure 6 . When the resin layer 12 consists only of an adhesive layer or an intermediary film, a multi-layer structure 10B can be manufactured using the same method as shown in Figure 6 . Specifically, while the glass layer 11 wound around the payout roll 300 is unwound from the payout roll 300 in the direction of the arrow, adhesive 122A is laminated on one surface of the glass layer 11, and then wound onto a take-up roll 350 having a desired inner diameter. If the adhesive 122A is in liquid form, it is cured using a curing device 400 to form the resin layer 12. The curing device 400 is, for example, an ultraviolet irradiation device or a heating device. Subsequently, by removing the take-up roll 350, a multi-layer structure 10B is obtained, in which the unit laminated structure 13, which is a laminated structure of the glass layer 11 and the resin layer 12, is laminated to the desired number of layers. The resin layer 12 is composed of an adhesive layer formed by curing the adhesive 122A. When an interlayer film such as EVA or PVB is used as the resin layer 12 , it is preferably wound up by the winding roller 350 while applying heat. Furthermore, when the resin layer 12 is composed solely of an interlayer film, the multi-layer structure 10B can be produced by thermocompression bonding the interlayer film-side surface of a unit laminate structure 13 of the glass layer 11 and the resin layer 12 to the glass layer 11 side of another unit laminate structure 13. In principle, during lamination, the temperature of the unit laminate structures 13 is raised to a temperature at which the glass layer 11 and the interlayer film can adhere to each other, thereby producing the multi-layer structure 10B. For example, when producing a multi-layer structure 10B having any columnar (cylindrical) structure, a method of pressing a heated roller against the outermost layer for pressure bonding can be used, either simultaneously with or after lamination. Furthermore, when a sheet of a unit laminate structure 13 is previously produced by laminating the glass layer 11 and the interlayer, the sheet of the unit laminate structure 13 can be obtained by increasing the temperature of the laminating rollers. Another method of obtaining the unit laminate structure 13 is to temporarily roll the glass layer 11 and the interlayer in an overlapping state, then place the roller under vacuum and use infrared light or the like to increase the temperature for bonding. (Resin Layer 12 Composed of a Resin Film and an Adhesive Layer or Adhesive Layer) Figure 7 illustrates a method for manufacturing a multi-layer structure in which the resin layer is composed of a resin film and an adhesive layer. When the resin layer 12 is composed of a resin film and an adhesive layer, for example, a multi-layer structure 10B can be manufactured using the method shown in Figure 7 . When the resin layer 12 is composed of a resin film and an adhesive layer, the multi-layer structure 10B can also be manufactured using the same method as shown in Figure 7 . Specifically, while the glass layer 11 wound on the payout roll 300 and the resin film 121 wound on the payout roll 310 are unwound from the payout roll 300 and the payout roll 310 in the directions indicated by the arrows, the adhesive 122A is laminated on both surfaces of the resin film 121, and then wound onto a take-up roll 350 having a desired inner diameter. By removing the take-up roll 350, a multi-layer structure 10B is obtained, in which the desired number of layers are laminated as a unit laminate structure 13, which is a laminate structure of the glass layer 11 and the resin layer 12. The resin layer 12 is composed of the resin film 121 and the adhesive layer 122 after the adhesive 122A has been cured. Note that, as shown in FIG8 , instead of laminating adhesive 122A on both surfaces of resin film 121, adhesive 122A may be laminated on one surface of glass layer 11 and one surface of resin film 121. In FIG8 , film-shaped adhesive 122A wound around feed rollers 320A and 320B is supplied to one surface of glass layer 11 and one surface of resin film 121. Alternatively, the following method may be used. First, as shown in FIG9A , while the glass layer 11 wound on the payout roll 300 and the resin film 121 wound on the payout roll 310 are unwound from the payout roll 300 and the payout roll 310 in the directions of the arrows, an adhesive 122A is laminated on one surface of the resin film 121 using a coater 500. The resin film 121 is then passed through a nip roll 330 and wound onto a take-up roll 360. In this manner, a composite roll 10X is produced in which the glass layer 11 and the resin film 121 are laminated via the adhesive 122A. Next, as shown in Figure 9B , while the composite roll 10X is unwound in the direction of the arrow, adhesive 122A is laminated on one surface of the resin film 121 using a coater 500 . The film is then wound onto a take-up roll 350 having a desired inner diameter. By removing the take-up roll 350 , a multi-layer structure 10B is obtained, in which the desired number of unit laminate structures 13, which are a laminate structure of glass layers 11 and resin layers 12, are laminated. In this case, the unit laminate structures 13 are laminated together via adhesive layers. As shown in Figure 9B , adhesive 122A may also be laminated on both surfaces of the resin film 121. It should be noted that in any of the methods shown in Figures 6 to 9B, for adhesives that require curing, it is necessary to cure them by heat or light while winding, or to cure them by heat or light after winding. Furthermore, for liquid adhesives, there are methods such as those shown in Figures 9A and 9B where a coating machine 500 is used to apply the adhesive to the resin film 121 for lamination, or as shown in Figure 7 where a liquid is formed in the winding portion to form an adhesive layer while winding. 6 to 9B , the thickness of the multi-layer structure 10B can be controlled by the number of windings. Furthermore, the inner diameter of the multi-layer structure 10B can be arbitrarily controlled by selecting the outer diameter of the winding roller 350 . Furthermore, when combining two or more multi-layer structures, for example, by winding one multi-layer structure using the above method and then winding multiple layers of films made of different thicknesses and materials thereon, a laminate can be produced in which different multi-layer structures are formed on the inside and outside of the cylinder. In this case, a configuration in which only a resin film that does not contain glass is wound with an adhesive can also be added. The multi-layer structure 10B is generally cylindrical, but by changing the shape of the winding roller 350 , it is possible to produce multi-layer structures 10B in various shapes as shown in FIG. 4A to FIG. 4D . Furthermore, by cutting the columnar structure of the multi-layer structure 10B, a semicircular or any other curved plate can be obtained, such as plate 10C shown in FIG10 or plate 10D shown in FIG11 . By combining plates 10C and 10D, various three-dimensional structures can be produced. Furthermore, by cutting the columnar structure of the multi-layer structure 10B, a multi-layer structure 10 as shown in FIG1 or a multi-layer structure 10A as shown in FIG2 can be produced. [Applications] The multi-layer structure of the present embodiment can be used for industrial piping, building materials, display cases, curved windows, and the like. Thus, the multi-layer structure of this embodiment comprises glass layers and resin layers having a thickness of 10µm to 200µm, with a laminated structure of one glass layer and one resin layer serving as a unit laminated structure. In the thickness direction of the multi-layer structure, the number of unit laminated structures is 5 to 20,000. Thus, while employing a multi-layer composite structure of glass layers and resin layers that absorbs high-intensity impacts, the multi-layer structure of this embodiment is lightweight and can be arbitrarily formed into not only flat surfaces but also curved surfaces and cylindrical shapes. Preferred embodiments have been described in detail above, but the present invention is not limited to the above embodiments and various modifications and substitutions can be made to the above embodiments without departing from the scope of the claims. This international application claims the benefit of priority based on Japanese Patent Application No. 2019-175837, filed on September 26, 2019, and the entire contents of Japanese Patent Application No. 2019-175837 are incorporated herein by reference. 10, 10A, 10B: Multi-layer structure 10C, 10D: Plate 11: Glass layer 12: Resin layer 13: Unit laminate structure 121: Resin film 122: Adhesive layer 122A: Adhesive FIG1 is a perspective view illustrating a multi-layer structure according to the present embodiment. FIG2 is a perspective view illustrating a multi-layer structure according to a first variant of the present embodiment. FIG3 is a perspective view illustrating a multi-layer structure according to a second variant of the present embodiment. FIG4A is a cross-sectional view illustrating the shape of a cross section of the multi-layer structure according to the present embodiment (part one). FIG4B is a cross-sectional view illustrating the shape of a cross section of the multi-layer structure according to the present embodiment (part two). FIG4C is a cross-sectional view illustrating the shape of a cross section of the multi-layer structure according to the present embodiment (part three). FIG4D is a cross-sectional view illustrating the shape of a cross section of the multi-layer structure according to the present embodiment (part four). FIG5A is a cross-sectional view illustrating the structure of a resin layer according to the present embodiment (part one). FIG5B is a cross-sectional view illustrating the structure of a resin layer according to the present embodiment (part two). FIG6 is a diagram illustrating a method for manufacturing a multi-layer structure in which the resin layer consists only of an adhesive layer. FIG7 is a diagram illustrating an example of a method for manufacturing a multi-layer structure in which a resin layer is composed of a resin film and an adhesive layer (part one). FIG8 is a diagram illustrating an example of a method for manufacturing a multi-layer structure in which a resin layer is composed of a resin film and an adhesive layer (part two). FIG9A is a diagram illustrating an example of a method for manufacturing a multi-layer structure in which a resin layer is composed of a resin film and an adhesive layer (part three). FIG9B is a diagram illustrating an example of a method for manufacturing a multi-layer structure in which a resin layer is composed of a resin film and an adhesive layer (part four). FIG10 is a stereoscopic diagram showing an example of a columnar structure of a multi-layer structure in which the present embodiment is cut off (part one). FIG11 is a stereoscopic diagram showing an example of a columnar structure of a multi-layer structure in which the present embodiment is cut off (part two). 10: Multi-layer structure 11: Glass layer 12: Resin layer 13: Unit stacking structure t1: thickness of the glass layer t2: Thickness of the resin layer

Claims

1. A multilayer structure having a glass layer with a thickness of 10µm to 200µm and a resin layer, wherein a stacked structure of one glass layer and one resin layer is used as a unit stacked structure, the resin layer being composed of an ultraviolet-curable epoxy resin adhesive, and the number of the unit stacked structures in the thickness direction of the multilayer structure being 5 to 20,000 layers.

2. The complex layer construct as described in claim 1, wherein, In this unit laminate structure, the resin layer has: a resin film that is flexible; and an adhesive layer or bonding layer disposed between the glass layer and the resin film.

3. The complex layer construct as described in claim 1, wherein, In this unit layered structure, the resin layer is the intermediate film.

4. The complex layer construct as described in claim 3, wherein, The intermediate membrane is made of polyvinyl acetal resin or polyhalogenated ethylene resin.

5. A complex layered structure as described in any one of claims 1 to 4, wherein, The unit is stacked on top of each other by adhesive or bonding layers.

6. A complex layered structure as described in any one of claims 1 to 4, wherein, The complex multilayered structure is cylindrical.

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